Compressor isolation molded insert

ABSTRACT

An assembly includes a base pan having an opening formed therein and an insert mountable to the base pan within the opening. The insert is connectable to a compressor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Application No. 63/352,789, filed Jun. 16, 2022, the contents of which are incorporated by reference herein in their entirety.

BACKGROUND

Exemplary embodiments of the present disclosure relate generally to heating, ventilation, and air conditioning (HVAC) systems and, more particularly, to base pans for outdoor units (often referred to as condenser units) in residential air conditioning and heat pump applications.

The current base pan used in condenser units is stamped sheet metal that is then painted to reduce corrosion. Because the condenser unit is suitable for use with a plurality of different compressors having varying capacities based on the system application, a different base pan is designed for each specific compressor configuration.

BRIEF DESCRIPTION

According to an embodiment, an assembly includes a base pan having an opening formed therein and an insert mountable to the base pan within the opening. The insert is connectable to a compressor.

In addition to one or more of the features described above, or as an alternative, in further embodiments the insert if one of a plurality of interchangeable inserts mountable within the opening.

In addition to one or more of the features described above, or as an alternative, in further embodiments each of the plurality of inserts has a different configuration associated with a different compressor.

In addition to one or more of the features described above, or as an alternative, in further embodiments the base pan is formed from a composite material.

In addition to one or more of the features described above, or as an alternative, in further embodiments the insert further comprises a base having a lower surface and a sidewall protruding from the lower surface of the base. The base extends beyond the sidewall to form an overhang configured to overlap with a surface of the base pan when installed within the opening.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising an isolator material being positioned between the overhang and the surface of the base pan.

In addition to one or more of the features described above, or as an alternative, in further embodiments at least one notch is formed in an outer periphery of the base such that a clearance exists between the base pan and the base of the insert at the at least one notch.

In addition to one or more of the features described above, or as an alternative, in further embodiments the insert is mountable to the base pan via a snap fit connection.

In addition to one or more of the features described above, or as an alternative, in further embodiments the insert further comprises at least one resilient tab protruding from the base and the base pan further comprises a groove, a portion of the at least one resilient tab being engagable with the groove.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising an isolator material positioned between the insert and a portion of the compressor that is connectable to the insert.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising another insert mountable to the base pan within the opening, the another insert being connectable to a another compressor, wherein a configuration of the another insert is different from the insert.

According to an embodiment, an assembly includes an insert positionable within a corresponding opening formed in a base pan and a compressor connectable to the insert. The insert includes a base having an upper surface and a lower surface and an isolator material positioned between the upper surface of the insert and the compressor. The compressor is connectable to the insert at a position offset from the upper surface of the base.

In addition to one or more of the features described above, or as an alternative, in further embodiments the insert further comprises at least one mounting post extending from the upper surface, the compressor being connectable to a distal end of the at least one mounting post.

In addition to one or more of the features described above, or as an alternative, in further embodiments the isolator material is positioned at the distal end of the at least one mounting post.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising a threaded insert arranged adjacent to the distal end of the at least one mounting post.

In addition to one or more of the features described above, or as an alternative, in further embodiments the insert further comprises another the isolator material positioned at a portion of the lower surface of the base configured to overlap with the base pan.

According to an embodiment, an insert is receivable within a corresponding opening formed in a base pan of an outdoor coil unit. The insert includes a base having an upper surface and a lower surface and a sidewall protruding from the lower surface of the base. The base extends beyond the sidewall to form an overhang configured to overlap with a surface of the base pan when installed within the opening. An isolator material is positioned about the insert and is configured to absorb vibration.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising at least one mounting post extending from the upper surface of the base.

In addition to one or more of the features described above, or as an alternative, in further embodiments the isolator material is arranged at a distal end of the at least one mounting post.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising at least one notch formed in an outer periphery of the base.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 is perspective view of an exemplary outdoor unit according to an embodiment;

FIG. 2A is a perspective view of an exemplary base pan having an insert and a portion of a compressor connected thereto according to an embodiment;

FIG. 2B is a perspective view of the base pan of FIG. 2A with the insert removed according to an embodiment;

FIG. 3 is a perspective view of an exemplary insert according to an embodiment;

FIG. 4 is a perspective view of an underside of the insert of FIG. 3 when installed within a base pan according to an embodiment;

FIG. 5 is a top perspective cross-sectional view of an interface between the insert and the base pan according to an embodiment;

FIG. 6 is a bottom perspective cross-sectional view of the interface between the insert and the base pan according to an embodiment;

FIG. 7 is a perspective view of a portion of an insert according to an embodiment;

FIG. 8 is a perspective view of an exemplary base pan having another insert according to an embodiment;

FIG. 9 is a perspective view of a side of an exemplary insert according to an embodiment;

FIG. 10 is a top perspective cross-sectional view of the connection between a compressor and the insert according to an embodiment; and

FIG. 11 is a perspective view of an exemplary insert according to an embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

Referring now to FIG. 1 , an exemplary outdoor unit 20 of heating, ventilation, and air conditioning (HVAC) system is illustrated. The outdoor unit 20 includes a heat exchanger 22 having a generally square structure, although embodiments where the heat exchanger 22 is rectangular, cylindrical, or another shape are also within the scope of the disclosure. As shown, the outdoor unit 20 additionally includes a base pan 24 arranged at the bottom of the outdoor unit 20 and configured to hold the heat exchanger 22 in place. A compressor 26 is arranged in fluid communication with the heat exchanger 22. As shown, the compressor 26 is mounted to the base pan 24 at a central location position within the interior of the heat exchanger 22. The compressor 26 is operable to pump a heat transfer fluid through a vapor compression cycle. Examples of the heat transfer fluid contemplated for use in the outdoor unit 20 described herein include refrigerants, CO2, oil, brine, and other suitable fluids. Disposed in contact with a surface of the heat exchanger 22 is a fan assembly 28 configured to draw ambient air radially inward, through the heat exchanger 22, after which the air is discharged upwardly through an opening 30.

With reference now to FIG. 2 , an exemplary base pan 24 is illustrated in more detail. The base pan 24 may be formed from any suitable material, including but not limited to metal, plastic, and a composite material for example. As shown, an opening 32 is formed at a central portion of the base pan 24. In the illustrated, non-limiting embodiment, the shape of the opening 32 includes a first sidewall 34 and a second sidewall 36 arranged to form a corner, and a curved wall 38 connecting the distal ends of the first and second sidewall 34, 36. However, it should be understood that an opening 32 having any suitable configuration is within the scope of the disclosure. A lip 40 (see FIG. 4 ) may extend from a surface 42 of the base pan 24, the lip 49 being arranged about all or at least a portion of the periphery of the opening 32.

A plurality of interchangeable inserts are positionable within the opening 32. Each insert 50 may be associated with a compressor having a different mounting configuration. In certain instances, the different compressors may have varying capacities. As will be discussed in more detail below, the insert 50 may be removably coupled to the base pan 24, such as via a plurality of fasteners, a snap fit connection, or in another suitable manner.

An exemplary insert 50 is illustrated in more detail in FIGS. 3-10 . As shown, a configuration of the insert 50 is complementary to the opening 32 formed in the base pan 24. More specifically, a size and shape of the insert 50 is generally equal or identical to the size and shape of the opening 32 that the insert 50 is receivable within the opening 32 to substantially seal the opening 32.

The insert 50 may be formed as a solid body, or alternatively, may be a formed or molded component having a non-uniform configuration, such as to reduce material and the weight of the insert 50. As shown, the insert 50 includes a generally planar base 52 having a lower surface 54 and at least one sidewall 56 extending from the lower surface. The at least one sidewall 56 may but need not wrap about a substantial entirety of a periphery of the insert 50. In the illustrated, non-limiting embodiment, the at least one sidewall 56 is oriented substantially perpendicular to the lower surface 54 of the base 52; however, embodiments where a sidewall 56 is arranged at another angle relative to the base 52 are also contemplated herein.

In an embodiment, the size and shape defined by the at least one sidewall 56 is generally equal to the size and shape of the opening 32 defined by the lip 40. Accordingly, when the insert 50 is installed within the opening 32, a surface of the at least one sidewall 56 is arranged in contact with an adjacent surface of the lip 40. The at least one sidewall 56 may be spaced radially inward from the outer periphery of the insert 50. As a result, a portion of the base 52 extends beyond the at least one sidewall 56 and therefore forms an overhang 58 relative to the at least one sidewall 56. In such embodiments, when the insert 50 is installed within the opening 32 of the base pan 24, the overhang 58 is configured to overlap a corresponding surface 60 (FIG. 5 ) of the base pan 24. In the illustrated, non-limiting embodiment of FIG. 5 , the base pan 24 includes a flange 62 extending radially from a wall 64 towards an interior of the opening 32, the flange 62 defines the surface 60 such that the overhang 58 of the base 52 not only overlaps the flange 62, but may also abut the adjacent wall 64.

In an embodiment, at least one notch 66 is formed at the outer periphery of the base 52. Although a rectangular notch 66 is illustrated in the FIGS., it should be understood that a notch 66 having any suitable configuration is within the scope of the disclosure. When the insert 50 is installed within an opening 32 of the base pan 24, the notch 66 defines a gap or clearance 68 between the base pan 24 and the insert 50. Inclusion of these notches 66 may limit transmission of vibration to and from the compressor 26.

In the illustrated, non-limiting embodiment, the insert 50 is connectable to the base pan 24 via a snap fit connection. As shown, one or more resilient tabs 70 protrude downwardly from the lower surface 54 of the base 52 and are engageable with a corresponding groove 74 formed in the lip 40. Although four equidistantly spaced tabs 70 are illustrated, embodiments having another number of tabs 70, such as one tab, two tabs, three tabs, or more than four tabs for example are also within the scope of the disclosure. In addition, although a tab 70 is shown as being positioned generally adjacent one of the notches 66, embodiments where one or more or the tabs 70 are located at another position about the insert 50 are also contemplated herein. The tabs 70 may be biased at an outward angle relative to the lower surface 54 of the base 52. Further, due to this bias, a foot 72 formed at a distal end of the tab 70 may be configured to abut a surface of the groove 74 to restrict movement of the insert 50 relative to the lip 40, and therefore the base pan 24.

The insert 50 is connectable to the compressor 26 at one or more connection points. In an embodiment, as shown in FIGS. 3-10 , at least one mounting post 76 extends from the upper surface 78 of the insert 50, the at least one mounting post 76 forming the connection with the compressor 26 as will be described in more detail below. The at least one mounting post 76 may be integrally formed with the upper surface 78 of the insert 50, such as through an injection molding or thermoforming process for example, or alternatively, may be removably coupled thereto. In the illustrated, non-limiting embodiment, the insert 50 includes a plurality of mounting posts 76, specifically four mounting posts arranged in a generally square configuration. However, it should be understood that in other embodiments, an insert may have a single mounting post, two mounting posts, three mounting posts, or more than four mounting posts. The total number of mounting posts 76, and further the position of the mounting posts 76 relative to the upper surface 78 will depend on the configuration of the compressor 26 intended for use with an insert 50. Accordingly, the position of one or more mounting posts 76 of a first insert, such as the insert shown in FIG. 3 , may be the same as, or may be different than the position of one or more mounting posts of a second insert, such as the insert shown in FIG. 8 .

As shown, each of the mounting posts 76 includes at least one sidewall 80 extending from the upper surface 78 to a distal end thereof. Accordingly, an interior 82 of each mounting post 76 defined by the one or more sidewalls 80 is substantially hollow. In the illustrated, non-limiting embodiment, a mounting collar 84 is arranged at a position offset from the upper surface 78 of the base 52, such as at or adjacent to the distal end of the sidewall 80 for example. An outer diameter of the mounting collar 84 may be smaller than the inner diameter of the mounting post 76, and in an embodiment, the mounting collar 84 is arranged generally centrally relative to the mounting post 76, such as coaxially therewith. A plurality of arms 86 may extend from the sidewall 80 and connect to an outer periphery of the mounting collar 84 to support the mounting collar 84. In such embodiments, the arms 86 may be spaced about a periphery of the mounting collar 84. However, in an embodiment, a flange may extend from the distal end of the of the sidewall 80 to the outer periphery of the mounting collar 84 about a substantial entirety of the mounting collar 84, thereby sealing the distal end of the mounting post 76.

As shown in the cross-sectional view of FIG. 10 , the mounting collar 84 may extend vertically beyond the distal end of the sidewall 80 in a first direction, and in some embodiments, in both a first direction and a second, opposite direction. The mounting collar 84 includes a central opening 87 configured to receive a fastener 88. In the illustrated, non-limiting embodiment, an insert 90 including a coupling mechanism 92, such as plurality of threads for example, is positioned within the opening 87 of the mounting collar 84 and is configured to receive a fastener 88. In other embodiments the coupling mechanism may be directly formed into a surface of the mounting collar 84.

A post isolator 94 may be arranged at the distal end of each mounting post 76, and extend about the outer periphery of the mounting collar 84. Alternatively, or in addition, a base isolator 96 may be located between the base 52 and a surface 60 of the base pan 24. In the illustrated, non-limiting embodiment, the base isolator 96 is arranged at the lower surface 54 of the overhang 58 of the base 52. Inclusion of the post isolators 94 and/or the base isolator 96 is operable to limit the transmission of vibration between the compressor 26 and the base pan 24 via the insert 50. The post isolators 94 and/or the base isolator 96 may be formed from any suitable material, including but not limited to a resin or an injection molded urethane. Further, the post and base isolators 94, 96 may be separate components connectable during installation of the insert 50, or alternatively, may be integrally formed with the insert, such as via an over-molding process for example. In an embodiment, the post isolators 94 and/or base isolator 96 is formed form a thermoplastic elastomer via a two shot or rotary injection molding process.

It should be understood that the insert 50 illustrated and described herein is intended as an example only and that an insert having any suitable configuration for connecting to a compressor 26 is contemplated herein. In an embodiment, shown in FIG. 11 , the insert 50′ has a planar surface 78′ and a plurality of openings (not shown) may be formed in the insert 50′. Each opening may be configured to receive a fastener 88′ coupling the compressor 26 thereto, and therefore forms a portion of a connection point between the compressor 26 and the insert 50′. In such embodiments, the compressor 26 is similarly offset from the surface 78′ of the insert 50′ by a distance. A material 98′ configured to function as an isolator by absorbing vibrations may be arranged between the compressor 26 and the surface 78′ of the insert 50′. The material 98′ may be a standard isolator block or may have another configuration. A coupling mechanism (not shown), such as threads for example, may be formed at an interior surface of the isolator material 98′, or alternatively, an insert 90′ having a coupling mechanism formed therein may be arranged within the opening of the isolator material configured to receive the fastener 88′.

An outdoor unit 20 using a base pan 24 having an opening 32 formed therein configured to receive one of a plurality of inserts allows for the use of a single universal base pan, thereby eliminating the need for a different base pan for each system application. Further, the inserts may be easily manufactured, making the manufacturing process automation friendly and reducing the overall cost of the outdoor unit.

The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.

While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims. 

What is claimed is:
 1. An assembly comprising: a base pan having an opening formed therein; and an insert mountable to the base pan within the opening, the insert being connectable to a compressor.
 2. The assembly of claim 1, wherein the insert is one of a plurality of interchangeable inserts mountable within the opening.
 3. The assembly of claim 2, wherein each of the plurality of inserts has a different configuration associated with a different compressor.
 4. The assembly of claim 1, wherein the base pan is formed from a composite material.
 5. The assembly of claim 1, wherein the insert further comprises: a base having a lower surface; and a sidewall protruding from the lower surface of the base, wherein the base extends beyond the sidewall to form an overhang configured to overlap with a surface of the base pan when installed within the opening.
 6. The assembly of claim 5, further comprising an isolator material being positioned between the overhang and the surface of the base pan.
 7. The assembly of claim 5, wherein at least one notch is formed in an outer periphery of the base such that a clearance exists between the base pan and the base of the insert at the at least one notch.
 8. The assembly of claim 5, wherein the insert is mountable to the base pan via a snap fit connection.
 9. The assembly of claim 8, wherein the insert further comprises at least one resilient tab protruding from the base and the base pan further comprises a groove, a portion of the at least one resilient tab being engagable with the groove.
 10. The assembly of claim 1, further comprising an isolator material positioned between the insert and a portion of the compressor that is connectable to the insert.
 11. The assembly of claim 1, further comprising another insert mountable to the base pan within the opening, the another insert being connectable to a another compressor, wherein a configuration of the another insert is different from the insert.
 12. An assembly comprising: an insert, the insert being positionable within a corresponding opening formed in a base pan; and a compressor, the compressor being connectable to the insert; wherein the insert further comprises: a base having an upper surface and a lower surface; an isolator material positioned between the upper surface of the insert and the compressor, wherein the compressor is connectable to the insert at a position offset from the upper surface of the base.
 13. The assembly of claim 12, wherein the insert further comprises at least one mounting post extending from the upper surface, the compressor being connectable to a distal end of the at least one mounting post.
 14. The assembly of claim 13, wherein the isolator material is positioned at the distal end of the at least one mounting post.
 15. The assembly of claim 13, further comprising a threaded insert arranged adjacent to the distal end of the at least one mounting post.
 16. The assembly of claim 12, wherein the insert further comprises another the isolator material positioned at a portion of the lower surface of the base configured to overlap with the base pan.
 17. An insert receivable within a corresponding opening formed in a base pan of an outdoor unit, the insert comprising: a base having an upper surface and a lower surface; a sidewall protruding from the lower surface of the base, wherein the base extends beyond the sidewall to form an overhang configured to overlap with a surface of the base pan when installed within the opening; and an isolator material positioned about the insert and configured to absorb vibration.
 18. The insert of claim 17, further comprising at least one mounting post extending from the upper surface of the base.
 19. The insert of claim 18, wherein the isolator material is arranged at a distal end of the at least one mounting post.
 20. The insert of claim 17, further comprising at least one notch formed in an outer periphery of the base. 